Footwear and Production Method Thereof

ABSTRACT

A method of producing a foamed footwear includes the steps of wearing around a footwear last with an inner covering housing, coating a first partition layer made of mixed rubber material on an outer surface of the inner covering housing, covering on a foaming raw material and an outer decorating fabric, attaching to the bottom side of the footwear last with a footwear sole, attaching to an outer surface of the outer decorating fabric with necessary reinforcing elements and necessary decorating elements, and heating in a vulcanization reactor. The foaming raw material undergoes a foaming reaction process, so that the footwear sole, the necessary reinforcing elements, and the necessary decorating element undergo a vulcanizing reaction process to enhance rubber properties thereof. Both of the inner surface and outer surface of the footwear has an aesthetic appearance. The production efficiency is increased and unnecessary waste of raw material is avoid.

NOTICE OF COPYRIGHT

A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to any reproduction by anyone of the patent disclosure, as it appears in the United States Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.

BACKGROUND OF THE PRESENT INVENTION

1. Field of Invention

The present invention relates to a footwear and production method thereof, and more particularly to a method of producing footwear comprising a shoe body having an integral foaming layer and a footwear having an integral foaming layer produced by such method.

2. Description of Related Arts

Referring to FIG. 1 to FIG. 2 of the drawings, a conventional foam shoe 10 comprises a foaming layer 13 provided in the shoe body 11 and the sole 12, enabling the foam shoe 10 to have advantages such as pliable and comfortable, thermal insulation and waterproof. Referring to FIG. 3 to FIG. 10 of the drawings, a method of producing the conventional foam shoe 10 comprises the following steps:

A foaming raw material 20 is foamed to a foamed block 21 having a predetermined thickness. Trim and remove any unevenly foamed outer surface 22 formed on the top side and lateral side of the foamed block 21. Then, the foamed material 21 is sliced into a plurality of foaming panels 23 with a desired thickness (as shown in FIG. 3). Each of the two sides of the foaming panels 23 are attached with an inner covering fabric layer 14 and an outer decorating fabric layer 15 (as shown in FIG. 4). The foaming panels 23 are each cut into a left shoe plate 25, a right shoe plate 26, and a midsole plate 27 (as shown in FIG. 5 and FIG. 6), wherein the left shoe plate 25 and the right shoe plate 25 are sewed together along the outer contour edge thereof while their bottom edges are sewed with the midsole plate 27 along the outer contour edge thereof, so as to form a shoe-type foaming sleeve 28, which has an opening 29 provided at a top end thereof to communicate the inside thereof (as shown in FIG. 7).

The foaming sleeve 28 is encased on a shoe last 30 and that the shoe last 30 and the foaming sleeve 28 are in contact with each other. Other shoe parts such as a sole 12, reinforcing elements 16, 17, decorating elements 18, 19 are adhered to a bottom surface and an outer surface of the foaming sleeve 28 at a position with respect to the shoe last 30 (as shown in FIG. 9 and FIG. 10). These shoe parts are made of mixed rubber material before vulcanization. Finally, shoe parts such as the sole 12, reinforcing elements 16, 17 and the decorating elements 18, 19 are thus vulcanized after a vulcanization process in a vulcanization reactor so as to enhance and increase the rubber properties thereof. After a cooling process, a foam shoe 10 is made.

However, the above conventional producing method has several disadvantages.

Firstly, the unevenly foamed outer surface 22 with of the foamed block 21 that has a predetermined thickness should be trimmed and removed, so that it not only wastes raw material but also increases additional production procedures, reducing the production efficiency. Also, the trimmed raw material is a waste material that causes issues of environmental protection and increases the production cost of the foam shoe 10.

Secondly, it is time-consuming to cut the foamed block 21 into panels according to the thickness required. Also, the two sides of each of the foaming panels 23 must be laminated with the inner covering fabric layer 14 and the outer decorating fabric layer 15 respectively. Therefore, the next cutting step of the foaming panel 23 can only be carried out after the laminating adhesive is dried. The tedious production process renders the efficiency of the production of the foam shoe 10 impractically to elevate.

Thirdly, it is also time-consuming to cut the foaming panel 23 which is adhered with the inner covering fabric layer 14 and the outer decorating fabric layer 15 into the left shoe plate 25, the right shoe plate 26, and the midsole plate 27, and the left-over material becomes waste material 24 that causes issues of environment pollution. Recycling and treatment of the waste material 24 would also result in higher production cost.

U.S. Pat. No. 2,256,329 (hereinafter called conventional art) disclosed a conventional method of producing a shoe that comprises the steps of vulcanizing and foaming in a mould, wherein if the steps are carried out without the limitation of the mould, rough and undulating surfaces will be formed on the final shoe product after the foaming step, causing the shoe products appearing unaesthetic.

SUMMARY OF THE PRESENT INVENTION

A main object of the present invention is to provide a foamed footwear and a production method thereof, wherein the parts and foaming layer of the foamed footwear undergo a vulcanizing reaction and a foaming reaction at the same time for being integrated with the shoe body, so as to produce the foamed footwear, so that the conventional tedious production steps such as pre-foaming of the foaming layers, cutting, trimming, sewing, and etc. of the foam shoe can thus be eliminated, and the unnecessary waste of material can also be avoided.

Additional advantages and features of the invention will become apparent from the description which follows, and may be realized by means of the instrumentalities and combinations particular point out in the appended claims.

According to the present invention, the foregoing and other objects and advantages are attained by a method of producing footwear, comprising the following steps.

Wear around a footwear last with a stocking-shape inner covering housing, made of inner lining fabric, in such a manner that the inner covering housing is fittingly attached to an outer surface of the footwear last.

Coat a first partition layer, made of mixed rubber material, on an outer surface of the inner covering housing. Alternatively, the first partition layer is able to be pre-coated on the outer surface of the inner covering housing before the inner covering housing is worn around the footwear last. Alternatively, the first partition layer is coated on a lateral side of a flat inner covering fabric, and then the flat inner covering fabric is sewed to form a stocking-shape inner covering housing, wherein the first partition layer is provided on the outer surface of the inner covering housing.

Cover and attach one or more pieces of foaming raw material, which have not been undergone a foaming process, to an outer surface and a bottom surface of the inner covering housing, wherein the first partition layer has an appropriate hardness and impermeability in comparison with the above foaming raw material attached to the inner covering housing.

Cover and attach one or more pieces of outer decorating fabric to an outer surface of the foaming raw material, wherein a bottom surface of the foaming raw material is not attached with the outer decorating fabric, wherein an inner surface of the outer decorating fabric is pre-coated with a second partition layer, made of mixed material containing rubber ingredient, wherein the second partition layer has an appropriate hardness and impermeability in comparison with the foaming raw material.

Attach a footwear sole, necessary reinforcing elements, and necessary decorating elements, which are made of mixed material containing rubber ingredient before vulcanization reaction, to an outer surface of the outer decorating fabric. Then, heat in a vulcanizing reactor, wherein the foaming raw material undergoes a foaming reaction process, so that the footwear sole, the necessary reinforcing elements, and the necessary decorating elements undergo a vulcanizing reaction to enhance and increase their rubber properties.

During the foaming reaction, an evenly foaming and expanding of the foaming raw material is restricted between the first partition layer on the outer surface of the inner covering housing and the second partition layer on the inner surface of the outer decorating fabric, and also is restricted between the footwear sole and the first partition layer on the outer surface of the inner covering housing, wherein the foaming raw material, the footwear sole, the necessary reinforcing elements, the necessary decorating elements, the inner covering housing, and the outer decorating fabric are integrated and fused with each other to form an integral foamed footwear.

Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.

These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a conventional foam shoe.

FIG. 2 is a sectional view of the conventional foam shoe.

FIG. 3 is a schematic view illustrating the pre-foaming of the foaming raw material according to the conventional production method of the conventional foam shoe.

FIG. 4 is a schematic view illustrating the lamination to the foaming panel with an inner cover fabric and an outer decorating fabric according to the conventional production method of the conventional foam shoe.

FIG. 5 is a schematic view illustrating the cutting of the foaming panel into a left shoe plate, a right shoe plate, and a midsole plate according to the conventional production method of the conventional foam shoe.

FIG. 6 is a schematic view illustrating the foaming sleeve sewed by the left shoe plate, a right shoe plate, and midsole plate of FIG. 5.

FIG. 7 is a schematic view illustrating the putting the shoe last into the foaming sleeve according to the conventional production method of the conventional foam shoe.

FIG. 8 is a schematic view illustrating the aligning of the foaming sleeve with a shoe sole, necessary reinforcing elements and necessary decorating elements according to the conventional production method of the conventional foam shoe.

FIG. 9 is a schematic view illustrating the foaming sleeve adhering with the shoe sole, the necessary reinforcing elements and the necessary decorating elements according to the conventional production method of the conventional foam shoe.

FIG. 10 is a schematic view illustrating an inner covering housing wearing on a footwear last according to a preferred embodiment of the present invention.

FIG. 11 is a schematic view illustrating the attachment of unfoamed foaming raw material to the inner covering housing according to the above preferred embodiment of the present invention.

FIG. 12 is a schematic view illustrating an outer decorating fabric layer attached to the foaming material layer according to the above preferred embodiment of the present invention.

FIG. 13 is a schematic view illustrating an unvulcanized footwear sole, necessary reinforcing elements, and necessary decorating elements being attached to the outer decorating fabric layer according to the above preferred embodiment of the present invention.

FIG. 14 is a sectional view of the foamed footwear according the above preferred embodiment of the present invention.

FIG. 15 is a sectional view of an alternative mode of the foamed footwear according the above preferred embodiment of the present invention.

FIG. 16 is a schematic view illustrating outer surface of a flat inner covering fabric being coated with a separating layer and then preparing the stocking-shape inner covering housing according the above preferred embodiment of the present invention.

FIG. 17 is a sectional view of the inner covering housing according the above preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following description is disclosed to enable any person skilled in the art to make and use the present invention. Preferable embodiments are provided in the following description only as examples and modifications will be apparent to those skilled in the art. The general principles defined in the following description would be applied to other embodiments, alternatives, modifications, equivalents, and applications without departing from the spirit and scope of the present invention.

Referring to FIG. 10 to FIG. 14 of the drawings, a method of producing a foamed footwear is illustrated, which comprises the following steps.

(1) A stocking-shape inner covering housing 50 prepared from fabric having stretching ability is worn around a footwear last 40 (as shown in FIG. 10), wherein the footwear last 40 is a mould shaped and sized to meet the requirement of the final footwear product. The footwear last 40, according to this preferred embodiment, comprises a footwear sole portion 44, a footwear face portion 41, a footwear heel portion 42, a footwear tube portion 43, and etc., wherein the inner covering housing 40 has an opening 51 provided at a top side thereof to communicate with an inner cavity of the inner covering housing 50. Except the opening 51, outer contour edges of the inner covering housing 50 is bonded together to define the inner cavity with the opening 51. The inner covering housing 50 has a stretching ability and thus is fittingly attached to an outer surface of the footwear last 40. Then, a first partition layer 52 having rubber ingredients is coated on the outer surface of the inner covering housing 50. Alternatively, the first partition layer 52 is able to be coated on the outer surface of the inner covering housing 50 before the inner covering housing 50 is worn around the footwear last 40. Still, alternatively, the first partition layer 52 is able to be coated on a lateral side of a flat inner covering fabric 53, and then the flat inner covering fabric 53 is sewed to produce a stocking-shape inner covering housing 50 (as shown in FIG. 16), wherein the first partition layer 52 is provided on the outer surface of the inner covering housing 50 (as shown in FIG. 17). The first partition layer 52, which has a stretching flexibility, is adapted to stretch and shrink together with the inner covering housing 50. The first partition layer 52 has an appropriate hardness and impermeability with respect to the raw foaming materials 61, 62, 63 to be attached to the inner covering housing 50 in the next step.

(2) Two pieces of sheet shape foaming raw material 61, 62, 63, which have not been undergone a foaming reaction process yet, are covered on and attached to the inner covering housing 50 in positions with respect to the footwear sole portion 44, footwear face portion 41, footwear heel portion 42, footwear tube portion 43, and other parts of the footwear last 40 (as shown in FIG. 11). The constitution of the foaming raw material 61, 62, 63 includes rubber ingredient, and the shape and quantity of the sheet shape foaming raw material 61, 62, 63 are determined by the function and appearance of the foamed footwear 86. Accordingly, foaming raw material 61, 62, 63 of varied thickness and varied materials can be attached to different positions of the inner covering housing 50 at positions corresponding to the footwear last 40. It is worth mentioning that the foaming raw material 61, 62, 63 of varied different materials should all contain rubber ingredient, and the bonding agent should also contain rubber, so that, after the foaming reaction process, all the materials are able to be integrated and fused with each other.

(3) Three pieces of flat outer decorating fabric 71, 72, 73 are covered on and attached to an outer surface of the foaming raw material 61, 62 at positions with respect to the footwear sole portion 44, the footwear face portion 41, the footwear heel portion 42, the footwear tube portion 43, and other parts of the footwear last 40 (as shown in FIG. 12), wherein a second partition layer 75, which is made of mixed material containing rubber ingredient, is coated on an inner surface of each piece of the outer decorating fabric 71, 72, 73 respectively. The second partition layer 75 has an appropriate hardness and impermeability with respect to the foaming raw materials 61, 62. The shape and quantity of the outer decorating fabric 71, 72, 73 are determined by the design of the aesthetic appearance of the foamed footwear 86. According to special requirements, the material of the outer decorating fabric 71, 72, 73 can be various material other than cloth, such as plastic fabric, rubber fabric, PU fabric, natural leather, artificial leather, and any other material coated with a partition layer.

(4) A footwear sole 81, two necessary reinforcing elements 82, 83, and one or more necessary decorating elements 84, which are made from mixed rubber material that have been undergone a mixing process without a vulcanizing process, are attached to an outer surface of the outer decorating fabric 71, 72, 73 (as shown in FIG. 13). The shape, thickness, and size of the reinforcing elements 82, 83 are predetermined according to the functions of the foamed footwear 86. The reinforcing elements 82, 83 made of varied materials, in which rubber is a necessary ingredient, may be provided to different positions of the footwear body. The decorating elements 84 can be designed into any three dimensional shape or plane shape having aesthetic appearance according to the design of the foamed footwear. Or, decorating elements 84 of various color are attached to different positions of the footwear body to enhance its aesthetic appearance. Also, according to the present preferred embodiment, the bonding position of the outer decorating fabric 71 is provided at a rear lateral side of the footwear tube portion 43, and the elongated stripe shape flat decorating element 84 can be covered on the bonding position to enhance the aesthetic appearance thereof.

(5) Vulcanization reaction: the above semi-finished product is heated in a vulcanization reactor, which has a pressure of 3.5 kg/cm² and a temperature maintained between 120˜135° C., so that the footwear sole 81, the two necessary reinforcing elements 82, 83, and the necessary decorating elements 84 undergo a vulcanizing reaction process to enhance and increase rubber properties thereof, and that the footwear sole 81, the two necessary enforcing elements 82, 83, the necessary decorating elements 84, the inner covering housing 50, and the outer decorating fabric 71, 72, 73 are integrated to form an integral (one-piece) structure. The foaming raw materials 61, 62, 63 are expanded after the foaming reaction and the first partition layer 52 on the outer surface of the inner covering housing 50 and the second partition layer 75 on the inner surface of the outer decorating fabric 71, 72, 73 are made of mixed rubber having appropriate hardness and impermeability. Therefore, when undergoing the foaming process, the foaming and expanding of the foaming raw materials 61, 62, 63 is restricted between the first partition layer 52 on the outer surface of the inner covering housing 50 and the second partition layer 75 on the inner surface of the outer decorating fabric 71, 72, 73, and also is restricted between the footwear sole 81 and the first partition layer 52 on the outer surface of the inner covering housing 50. The foamed layer is thus integrated and fused with the footwear sole 81, the inner covering housing 50, the necessary decorating elements 84, and the outer decorating fabric 71, 72, 73 to form a final foamed footwear 86 product.

The production method of the foamed footwear 86 has the following advantages in comparison with the prior art.

Firstly, the disadvantage of complicated production process of the conventional foam shoe 10 is improved that the foam layer 76 does not required to undergo the foaming process beforehand, so that the foaming, cutting, rimming, and sewing steps in the production method of the conventional foamed shoe 10 are eliminated.

Secondly, the disadvantage of produced waste in the production process of the conventional foam shoe 10 is improved that the foam layer 76 of suitable shape and size is prepared by directly cutting the foaming raw material before undergoing the foaming process, so that the left-over foaming material can be collected and made into a new sheet of foaming raw material for use again. And thus, no waste is produced according to the production method of the foamed footwear of the present invention so that environment pollution is prevented.

Thirdly, the disadvantage of unevenly foaming is improved that the first partition layer 52 on the outer surface of the inner covering housing 50 and the second partition layer 75 on the inner surface of the outer decorating fabric 71, 72, 73, which have appropriate hardness and impermeability, provide a complete bather for the foaming raw materials 61, 62, 63, so that when the foaming raw material 61, 62, 63 is expanding during the foaming process, an excessive expanding at a particular point is prevented, and that the foaming and expanding of the foaming material 61, 62, 63 is restricted between the first partition layer 52 on the outer surface of the inner covering housing 50 and the second partition layer 75 on the inner surface of the outer decorating fabric 71, 72, 73, and also is restricted between the footwear sole 81 and the first partition layer 52 on the outer surface of the inner covering housing 50, so that the inner surface and outer surface of the foamed footwear 86 both provide a leveling aesthetic appearance.

Fourthly, because of the introducing of the first partition layer 52 and the second partition layer 75, the foamed footwear 86 is able to provide a leveling aesthetic appearance without any aiding of a mould couple during the vulcanization process, so as to reduce the cost of providing the mould and also facilitate the production of the foamed footwear 86.

Referring to FIG. 14 of the drawing, the foamed footwear produced by the above method comprises a footwear body 77 and a footwear sole 81, wherein, from outside to inside, the footwear body 77 comprises one or more reinforcing elements 82, 83, one or more decorating elements 84, outer decorating fabric layers 71, 72, 73, a second partition layer 75, a foam layer 76, an inner covering housing 50, and a first partition layer 52, wherein the reinforcing elements 82, 83 and the decorating element 84 are bonded to an outer side of the outer decorating fabric layers 71, 72, 73, the second partition layer 75 is provided on an inner surface of each outer decorating fabric layer 71, 72, 73, and the first partition layer 52 is provide on an outer surface of the inner covering housing 50, wherein the footwear sole 81 is provided at a bottom side of the foamed footwear, wherein another foaming layer 161 is formed between the footwear sole 81 and the first partition layer 52 on the outer surface of the inner covering housing 50. Alternatively, referring to FIG. 15 of the drawing, the outer decorating fabric 71, 72, 73 can be replaced by the rubber leather, and then the second partition layer 75 is no longer required to be coated on the inner surface of the outer decorating fabric 71, 72, 73. The foamed footwear produced by the above production method should enjoy the benefit such as pliable, comfortable, thermal insulation, and waterproof. And from a view of the outer surface of the outer decorating fabric 71, 72, 73, there is no rough and uneven surface formed from the uneven foaming of the foaming raw material.

One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.

It will thus be seen that the objects of the present invention have been fully and effectively accomplished. It embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims. 

What is claimed is:
 1. A method of producing a footwear, comprising the steps of: (a) wearing around a footwear last with a stocking-shape inner covering housing made of inner lining fabric, in such a manner that said inner covering housing is fittingly attached to an outer surface of said footwear last; (b) coating a first partition layer, made of mixed rubber material, on an outer surface of said inner covering housing; (c) covering and attaching at least a foaming raw material, which have not been undergone a foaming process, to an outer surface and a bottom surface of said inner covering housing, wherein said first partition layer has a predetermined hardness and impermeability in comparison with said foaming raw material to be attached to said inner covering housing; (d) covering and attaching at least an outer decorating fabric to an outer surface of said foaming raw material, wherein a bottom surface of said foaming raw material is not attached with said outer decorating fabric, wherein an inner surface of said outer decorating fabric is pre-coated with a second partition layer, made of mixed material containing rubber ingredient, wherein said second partition layer has a predetermined hardness and impermeability in comparison with said foaming raw material; (e) attaching a footwear sole, one or more necessary reinforcing elements, and one or more necessary decorating elements, which are made of mixed material containing rubber ingredient before vulcanization reaction, to an outer surface of said outer decorative fabric to form a semi-finished footwear to form a semi-finished footwear; and (f) undergoing said semi-finished footwear a foaming and vulcanizing reaction to enhance rubber properties of wherein said footwear sole, said necessary reinforcing elements, and said necessary decorating elements, wherein a foaming and expanding of said foaming material is restricted between said first partition layer on said outer surface of said inner covering housing and said second partition layer on said inner surface of said outer decorating fabric, and also is restricted between said footwear sole and said first partition layer on said outer surface of said inner covering housing, wherein said foaming raw material, said footwear sole, said necessary reinforcing elements, said necessary decorating elements, said inner covering housing, and said outer decorating fabric are integrated and fused with each other to produce a foamed footwear.
 2. The method, as recited in claim 1, wherein said first partition layer is pre-coated on said outer surface of said inner covering housing before said inner covering housing is worn around said footwear last.
 3. The method, as recited in claim 1, wherein said first partition layer is coated on a lateral side of a flat inner covering fabric, and then said flat inner covering fabric is sewed to form said stocking-shape inner covering housing, wherein said first partition layer is provided on said outer surface of said inner covering housing.
 4. The method, as recited in claim 1, wherein said outer decorating fabric is plastic fabric.
 5. The method, as recited in claim 1, wherein said outer decorating fabric is rubber fabric.
 6. The method, as recited in claim 1, wherein said outer decorating fabric is PU fabric.
 7. The method, as recited in claim 1, wherein said outer decorating fabric is natural leather without a second partition layer provided on an inner surface thereof.
 8. The method, as recited in claim 1, wherein said outer decorating fabric is artificial leather without a second partition layer provided on an inner surface thereof.
 9. The method, as recited in claim 1, wherein said outer decorating fabric is rubber leather without a second partition layer provided on an inner surface thereof.
 10. The method, as recited in claim 2, wherein said inner covering housing has a stretching ability, wherein said first partition layer also has a stretching flexibility and is stretched and shrunk together with said inner covering housing.
 11. The method, as recited in claim 3, wherein said inner covering housing has a stretching ability, wherein said first partition layer also has a stretching flexibility and is stretched and shrunk together with said inner covering housing.
 12. A footwear, comprising a footwear body and a footwear sole, wherein from outside to inside, said footwear body comprises at least a reinforcing element, at least a decorating element, at least an outer decorating fabric layer, a second partition layer, a foam layer, an inner covering housing, and a first partition layer, wherein said reinforcing element and said decorating element are bonded to an outer side of said outer decorating fabric layer, said second partition layer is provided on an inner surface of said outer decorating fabric layer, and said first partition layer is provide on an outer surface of said inner covering housing, wherein said footwear sole is provided at a bottom side of said footwear, wherein another foaming layer is formed between said footwear sole and said first partition layer on said outer surface of said inner covering housing.
 13. The footwear, as recited in claim 12, wherein said outer decorating fabric is plastic fabric.
 14. The footwear, as recited in claim 12, wherein said outer decorating fabric is rubber fabric.
 15. The footwear, as recited in claim 12, wherein said outer decorating fabric is PU fabric.
 16. The footwear, as recited in claim 12, wherein said outer decorating fabric is natural leather.
 17. The footwear, as recited in claim 12, wherein said outer decorating fabric is artificial leather. 